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BASIC SYSTEM
1)
Consider a simple hydraulic
1)
Consider a simple hydraulic
system consisting of a reservoir
system consisting of a reservoir
(A), electric drive motor (B), pump
(A), electric drive motor (B), pump
(C), relief valve (D), filter (E), flow
(C), relief valve (D), filter (E), flow
control valve (F), directional control
control valve (F), directional control
valve (G) and cylinder (H).
valve (G) and cylinder (H).
HH
2) Movement of the cylinder is
2) Movement of the cylinder is
controlled by the flow control
controlled by the flow control
valve (which determines the
valve (which determines the
speed of movement) and the
speed of movement) and the
directional control valve (which
directional control valve (which
determines which way the
determines which way the
cylinder moves).
cylinder moves).
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BASIC SYSTEM
When the solenoid valve is
When the solenoid valve is
energised, the cylinder piston will
energised, the cylinder piston will
extend or retract at a speed
extend or retract at a speed
determined by the flow control
determined by the flow control
valve. The solenoid valve itself
valve. The solenoid valve itself
therefore has no control over the
therefore has no control over the
cylinder speed.
cylinder speed.
BASIC SYSTEM
A three position solenoid valve can:
A three position solenoid valve can:
- extend the cylinder
- extend the cylinder
BASIC SYSTEM
A three position solenoid valve can:
A three position solenoid valve can:
- extend the cylinder
- extend the cylinder
- retract the cylinder
- retract the cylinder
BASIC SYSTEM
A three position solenoid valve can:
A three position solenoid valve can:
- extend the cylinder
- extend the cylinder
- retract the cylinder
- retract the cylinder
- stop the cylinder
- stop the cylinder
BASIC SYSTEM
1)
A proportional directional
1)
A proportional directional
valve can be thought of as the
valve can be thought of as the
dimmer switch equivalent of an
dimmer switch equivalent of an
electrical switch.
electrical switch.
BASIC SYSTEM
So in effect the proportional
So in effect the proportional
directional valve is acting as both a
directional valve is acting as both a
directional valve and a flow control
directional valve and a flow control
valve.
valve.
PROPORTIONAL VALVE
PROPORTIONAL VALVE
By varying the current to either
By varying the current to either
solenoid, the amount of spool
solenoid, the amount of spool
movement can be varied and hence the
movement can be varied and hence the
amount of flow through the valve can
amount of flow through the valve can
be controlled.
be controlled.
PROPORTIONAL VALVE
By varying the current to either
By varying the current to either
solenoid, the amount of spool
solenoid, the amount of spool
movement can be varied and hence the
movement can be varied and hence the
amount of flow through the valve can
amount of flow through the valve can
be controlled.
be controlled.
PROPORTIONAL VALVE
By varying the current to either
By varying the current to either
solenoid, the amount of spool
solenoid, the amount of spool
movement can be varied and hence the
movement can be varied and hence the
amount of flow through the valve can
amount of flow through the valve can
be controlled.
be controlled.
PROPORTIONAL VALVE
By varying the current to either
By varying the current to either
solenoid, the amount of spool
solenoid, the amount of spool
movement can be varied and hence the
movement can be varied and hence the
amount of flow through the valve can
amount of flow through the valve can
be controlled.
be controlled.
PROPORTIONAL VALVE
By varying the current to either
By varying the current to either
solenoid, the amount of spool
solenoid, the amount of spool
movement can be varied and hence the
movement can be varied and hence the
amount of flow through the valve can
amount of flow through the valve can
be controlled.
be controlled.
PROPORTIONAL VALVE
By varying the current to either
By varying the current to either
solenoid, the amount of spool
solenoid, the amount of spool
movement can be varied and hence the
movement can be varied and hence the
amount of flow through the valve can
amount of flow through the valve can
be controlled.
be controlled.
PROPORTIONAL SOLENOID
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So unlike a conventional
So unlike a conventional
solenoid valve, the electrical
solenoid valve, the electrical
current flowing through the
current flowing through the
coil of a proportional valve
coil of a proportional valve
needs to be regulated not
needs to be regulated not
just switched on or off.
just switched on or off.
The
construction
of
a
The
construction
of
a
proportional
solenoid
is
proportional
solenoid
is
however similar to that of an
however similar to that of an
on/off solenoid.
on/off solenoid.
The solenoid consists of:
The solenoid consists of:
- a coil (A)
- a coil (A)
- a frame (B)
- a frame (B)
- an armature (C)
- an armature (C)
- a pole piece (D)
- a pole piece (D)
- a push-pin (E)
- a push-pin (E)
The armature is enclosed in a
The armature is enclosed in a
core tube (F) and the whole
core tube (F) and the whole
assembly is often fully
assembly is often fully
encapsulated in a plastic resin
encapsulated in a plastic resin
material (G).
material (G).
PROPORTIONAL SOLENOID
When a voltage is applied to the
When a voltage is applied to the
coil connections, an electrical
coil connections, an electrical
current will flow through the
current will flow through the
coil.
coil.
PROPORTIONAL SOLENOID
PROPORTIONAL SOLENOID
PROPORTIONAL SOLENOID
PROPORTIONAL SOLENOID
PROPORTIONAL SOLENOID
PROPORTIONAL SOLENOID
I
F
The solenoid is designed so that
The solenoid is designed so that
the relationship between the
the relationship between the
solenoid force (F) and the coil
solenoid force (F) and the coil
current (I) is a linear one. This
current (I) is a linear one. This
means that the solenoid force
means that the solenoid force
depends only on the coil current.
depends only on the coil current.
PROPORTIONAL SPOOL
PROPORTIONAL SPOOL
PROPORTIONAL SPOOL
To control higher
To control higher
flow
rates,
the
flow
rates,
the
proportional
direct
proportional
direct
acting relief valve
acting relief valve
can be used as the
can be used as the
pilot stage of a twopilot stage of a twostage
relief
(or
stage
relief
(or
reducing valve).
reducing valve).
To control higher
To control higher
flow
rates,
the
flow
rates,
the
proportional
direct
proportional
direct
acting relief valve
acting relief valve
can be used as the
can be used as the
pilot stage of a twopilot stage of a twostage
relief
(or
stage
relief
(or
reducing valve).
reducing valve).
0.015
0.040
1.000
2.000
3.000
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MOTION CONTROL
Distance
time
MOTION CONTROL
Distance
Acceleration
time
MOTION CONTROL
Distance
Velocity
Acceleration
time
MOTION CONTROL
3. A smooth deceleration with minimal pressure peaks.
3. A smooth deceleration with minimal pressure peaks.
Distance
Deceleration
Velocity
Acceleration
time
FORCE CONTROL
Proportional valves can
Proportional valves can
also be used to control
also be used to control
the force output from an
the force output from an
actuator (for example in
actuator (for example in
press or plastic injection
press or plastic injection
moulding applications) by
moulding applications) by
controlling the pressure
controlling the pressure
applied to the actuator.
applied to the actuator.
Force
time
FORCE CONTROL
In such cases it is often
In such cases it is often
necessary to control not
necessary to control not
only
the
maximum
only
the
maximum
actuator pressure but
actuator pressure but
also the rate at which
also the rate at which
the pressure is applied
the pressure is applied
or removed.
or removed.
Force
time
FORCE CONTROL
In fact the machine
In fact the machine
cycle may consist of a
cycle may consist of a
series of ramps and
series of ramps and
holding periods all of
holding periods all of
which can be achieved
which can be achieved
with
just
the
one
with
just
the
one
proportional valve.
proportional valve.
Force
time
FORCE CONTROL
At the end of the
At the end of the
machine cycle the rate
machine cycle the rate
at which the pressure is
at which the pressure is
reduced is also critical in
reduced is also critical in
many processes.
many processes.
Force
time
FORCE CONTROL
Motion and force control
Motion and force control
can thus be achieved
can thus be achieved
using proportional valves,
using proportional valves,
and in some cases the
and in some cases the
same valve can be used
same valve can be used
for both motion and
for both motion and
force control. This is
force control. This is
usually referred to as
usually referred to as
PQ control ie. the
PQ control ie. the
control of both pressure
control of both pressure
(P) and flow (Q).
(P) and flow (Q).
Furthermore,
all
of
Furthermore,
all
of
these control functions
these control functions
can be achieved using
can be achieved using
electronic inputs to the
electronic inputs to the
valve thus providing a
valve thus providing a
simple interface to the
simple interface to the
machine controller.
machine controller.
ELECTRONIC CONTROL
24 V DC
24 V DC
24 V DC
24 V DC
24 V DC
24 V DC
24 V DC
24 V DC
VALVE TYPES
NON-FEEDBACK VALVE
Different types of proportional valves with differing levels of
Different types of proportional valves with differing levels of
performance are available to meet the requirements of a wide
performance are available to meet the requirements of a wide
range of applications. The simplest type of proportional
range of applications. The simplest type of proportional
directional valve balances the solenoid force against a spring
directional valve balances the solenoid force against a spring
compression force in order to position the spool within the
compression force in order to position the spool within the
valve body.
valve body.
NON-FEEDBACK VALVE
An input signal to the amplifier produces a corresponding
An input signal to the amplifier produces a corresponding
output current to the valve solenoid. This current creates a
output current to the valve solenoid. This current creates a
force on the valve spool thus moving it across until the
force on the valve spool thus moving it across until the
compression of the spring balances the solenoid force.
compression of the spring balances the solenoid force.
A small input signal thus creates a small opening of the valve.
A small input signal thus creates a small opening of the valve.
NON-FEEDBACK VALVE
Increasing the input signal gradually opens up the valve and
Increasing the input signal gradually opens up the valve and
allows more flow to pass through...
allows more flow to pass through...
NON-FEEDBACK VALVE
... until the valve is wide open and passing maximum flow.
... until the valve is wide open and passing maximum flow.
NON-FEEDBACK VALVE
1) For any input signal therefore, the spool is positioned by
1) For any input signal therefore, the spool is positioned by
balancing solenoid force against spring force. In practice
balancing solenoid force against spring force. In practice
however, other forces also act on the spool. Flow forces in
however, other forces also act on the spool. Flow forces in
particular are generated when flow passes through the valve
particular are generated when flow passes through the valve
and these will act with the spring to oppose the solenoid force
and these will act with the spring to oppose the solenoid force
and thus reduce the amount of spool opening.
and thus reduce the amount of spool opening.
NON-FEEDBACK VALVE
1) For any input signal therefore, the spool is positioned by
1) For any input signal therefore, the spool is positioned by
balancing solenoid force against spring force. In practice
balancing solenoid force against spring force. In practice
however, other forces also act on the spool. Flow forces in
however, other forces also act on the spool. Flow forces in
particular are generated when flow passes through the valve
particular are generated when flow passes through the valve
and these will act with the spring to oppose the solenoid force
and these will act with the spring to oppose the solenoid force
and thus reduce the amount of spool opening.
and thus reduce the amount of spool opening.
FEEDBACK VALVE
Valve performance can be increased by adding a spool position
Valve performance can be increased by adding a spool position
sensor to the valve. This sensor provides an electronic
sensor to the valve. This sensor provides an electronic
feedback signal to the amplifier and thus allows the spool to be
feedback signal to the amplifier and thus allows the spool to be
positioned much more accurately.
positioned much more accurately.
FEEDBACK VALVE
Increasing the input signal to the amplifier gradually opens the
Increasing the input signal to the amplifier gradually opens the
valve flow path.
valve flow path.
FEEDBACK VALVE
Increasing the input signal to the amplifier gradually opens the
Increasing the input signal to the amplifier gradually opens the
valve flow path.
valve flow path.
FEEDBACK VALVE
As before, flow forces will build up to oppose the solenoid
As before, flow forces will build up to oppose the solenoid
force and attempt to reduce the spool opening. Any reduction
force and attempt to reduce the spool opening. Any reduction
in opening is now detected by the spool sensor however and
in opening is now detected by the spool sensor however and
results in an increased output current from the amplifier and
results in an increased output current from the amplifier and
an increased force from the solenoid to counteract the flow
an increased force from the solenoid to counteract the flow
forces.
forces.
FEEDBACK VALVE
1) As the pressure drop and flow rate through the valve
1) As the pressure drop and flow rate through the valve
increase further, ultimately the flow forces will overcome the
increase further, ultimately the flow forces will overcome the
solenoid force and act to reduce the valve opening as with the
solenoid force and act to reduce the valve opening as with the
simple valve but this will now occur at a significantly greater
simple valve but this will now occur at a significantly greater
flow rate than before. For a given size therefore, a feedback
flow rate than before. For a given size therefore, a feedback
type valve will pass a greater flow than the equivalent nontype valve will pass a greater flow than the equivalent nonfeedback valve and the spool positioning will be more accurate.
feedback valve and the spool positioning will be more accurate.